DOD_4145-26M.pdf

DoD 4145.26-M

DOD Contractor’s Safety Manual For Ammunition and Explosives

March 13, 2008

UNDER SECRETARY OF DEFENSE

FOR ACQUISITION, TECHNOLOGY, AND LOGISTICS

DoD 4145.26-M, March 13, 2008

2 FOREWORD

This Manual is reissued under the authority of and in accordance with DoD Instruction 4145.26 (Reference (a)) and, accordingly, is applicable to all contractual actions entered into on or after the reissue date. The prior DoD 4145.26-M (Reference (b)), dated September 16, 1997, is hereby rescinded and superseded, yet will remain applicable and effective for contractual actions entered into on or after September 16, 1997 and before the reissue date. The Manual provides safety standards common to DoD and private industry ammunition and explosives (AE), operations, and facilities performing AE work or AE services under DoD contracts, subcontracts, purchase orders, or other procurement methods. DoD 6055.9-STD (Reference (c)) establishes these AE safety standards and serves as the primary source document for this Manual. The explosives safety requirements included in this Manual are consistent with Reference (c) so that AE safety standards for DoD Components and DoD contractors are equivalent.

Subpart 223.370 of the Defense Federal Acquisition Regulation Supplement (Reference (d)) requires contracting officers to incorporate this Manual in all AE procurement actions. The purchasing activity may include additional AE or related safety requirements that are not inconsistent with this Manual as it deems necessary. The Manual should be incorporated into AE procurement actions in order to legally bind the contractor to follow the provisions contained therein.

This revision removes the chapter on hazard component data statements and updates quantity distance requirements and basic AE safety principles.

Questions on interpretation of any requirement in this Manual by the contractor should be submitted through the contractor’s assigned administrative contracting officer to the procuring contracting officer for further review and resolution.

This Manual applies to the Office of the Secretary of Defense (OSD), the Military Departments (including their Reserve Components), the Office of the Chairman of the Joint Chiefs of Staff, Combatant Commands, the Office of the Inspector General of the Department of Defense, the Defense Agencies, the DoD Field Activities, and all other organizational entities in the Department of Defense (hereafter referred to collectively as the “DoD Components”).

This Manual is effective immediately, and is mandatory for use by all the DoD Components as specified in Reference (a).

3 FOREWORD

Forward recommendations for change to this Manual to:

Chairman Department of Defense Explosives Safety Board Room 856C, Hoffman Building I 2461 Eisenhower Avenue Alexandria, VA 22331-0600

RELEASABILITY. UNLIMITED. This Manual is approved for public release. Copies may be obtained through the Internet from the DoD Issuances Web Site at http://www.dtic.mil/whs/directives.

An electronic copy can also be obtained by contacting the Department of Defense Explosives Safety Board; Room 856C, Hoffman Building I; 2461 Eisenhower Avenue; Alexandria, VA 22331-0600; telephone at 703-325-2525.

4 TABLE OF CONTENTS

TABLE OF CONTENTS

FOREWORD 2

TABLE OF CONTENTS 4

ACRONYMS AND ABBREVIATIONS 11

REFERENCES 14

C1. CHAPTER 1 – INTRODUCTION 16

C1.1. Purpose 16 C1.2. Applicability 16 C1.3. Mandatory Requirements and Advisory Guidance 16 C1.4. Compliance with Mandatory Requirements 16 C1.5. Pre-Award Safety Survey 17 C1.6. Pre-Operational Safety Survey 18 C1.7. Post-Award Contractor Responsibilities 18 C1.8. Site and Construction Plans 19

C2. CHAPTER 2 - ACCIDENT INVESTIGATION AND REPORTING 21

C2.1. General 21 C2.2. Reporting Criteria 21 C2.3. Accident Investigation Requirements 21 C2.4. Telephone Report 22 C2.5. Written Report 22 C2.6. Technical Accident Investigation and Report 23

C3. CHAPTER 3 – GENERAL SAFETY REQUIREMENTS 24

C3.1. General 24 C3.2. Personnel and Material Limits 24 C3.3. SOPs 24 C3.4. Storage in Operating Buildings 26 C3.5. Housekeeping in Hazardous Areas 27 C3.6. Explosives Waste in Operating Areas 27 C3.7. Procedure Before Electrical Storms 28 C3.8. Precautions for Maintenance and Repairs to AE Equipment and Buildings 29 C3.9. Safety Hand Tools 30 C3.10. Operational Shields 30 C3.11. Protective Clothing 31 C3.12. Material Handling Equipment 31

5 TABLE OF CONTENTS

C3.13. Ignition Sources in Hazardous Areas 32 C3.14. Operational Explosives Containers 32 C3.15. Intraplant Rail Transportation 32 C3.16. Intraplant Motor Vehicle Transportation of AE 34 C3.17. Inspection of AE Mixing Equipment 35

C4. CHAPTER 4 - HAZARD CLASSIFICATION AND STORAGE 37

COMPATIBILITY SYSTEMS

C4.1. Hazard Classification 37 C4.2. Storage Compatibility 38

C5. CHAPTER 5 – QD PRINCIPLES, CRITERIA, AND SITING REQUIREMENTS 44

C5.1. General 44 C5.2. QD Principles 44 C5.3. Determining NEWQD 45 C5.4. General QD Rules 47 C5.5. Types of QDs 49 C5.6. Explosion Effects, Expected Consequences, Exposure Controls 50 C5.7. Permissible Exposures 54 C5.8. Hazardous Fragment Distance (HFD) 58 C5.9. IBD and PTRD 63

C5.10. ILD 64

C5.11. IMD 64

C5.12. HD 1.2 65

C5.13. HD 1.3 68

C5.14. HD 1.4 68

C5.15. HD 1.6 68

C5.16. HD 6.1 68

C5.17. Energetic Liquids 69 C5.18. Facilities Siting Criteria 75

C6. CHAPTER 6 - ELECTRICAL SAFETY REQUIREMENTS 85

FOR AE FACILITIES

C6.1. General 85 C6.2. Electrical Installations 85 C6.3. Lightning Protection 87 C6.4. Static Electricity and Grounding 88 C6.5. Electrical Test Equipment 93 C6.6. Humidification and Ionization 93

6 TABLE OF CONTENTS

C7. CHAPTER 7 - MANUFACTURING AND PROCESSING 94

PROPELLANTS

C7.1. General 94 C7.2. Properties of Propellants 94 C7.3. In-Process Hazards 95 C7.4. Separation of Operations and Building 96 C7.5. Equipment and Facilities 97 C7.6. In-Process Quantities and Storage 101 C7.7. Ingredients Processing 101 C7.8. Mixing 105 C7.9. Casting and Curing 105 C7.10. Extrusion Processes 106 C7.11. Propellant Loaded AE 106 C7.12. Disassembly 108 C7.13. Logistical Moves 108

C8. CHAPTER 8 - SAFETY REQUIREMENTS FOR MANUFACTURING AND 109

PROCESSING PYROTECHNICS

C8.1. General 109 C8.2. Properties of Pyrotechnic Material and Mixtures 109 C8.3. Process Requirements 111 C8.4. Spill Control 117 C8.5. Collection of Pyrotechnic Waste 117 C8.6. Cleaning of Pyrotechnic Processing Equipment 117 C8.7. Personal Protective Equipment 118 C8.8. Additional Controls 119 C8.9. Reworking Pyrotechnic Components 119 C8.10. Fire Protection 119

C9. CHAPTER 9 - AE STORAGE 120

C9.1. General 120 C9.2. Magazine Operational Regulations 120 C9.3. Stacking 120 C9.4. Unpackaged AE Items and Damaged Containers 121 C9.5. Maintenance and Repairs to Magazines 121 C9.6. Open Storage (Outdoors) 121 C9.7. Storage of Bulk Initiating Explosives 121 C9.8. Hazards of Long-Term Storage 122 C9.9. Rockets and Rocket Motors 122

C10. CHAPTER 10 - FIRE PROTECTION 123

C10.1. General 123

7 TABLE OF CONTENTS

C10.2. Fire Plan 123 C10.3. Smoking 123 C10.4. Hot Work Permits 123 C10.5. Portable Fire Extinguishers 123 C10.6. Fire Hazard Identification System 124 C10.7. Firefighting Procedures 125 C10.8. Automatic Sprinkler System 128 C10.9. Deluge Systems 128 C10.10. Firebreaks 129

C11. CHAPTER 11 - RISK IDENTIFICATION AND MANAGEMENT 130

C11.1. General 130 C11.2. Risk Management System 130 C11.3. Analytical Methods 131 C11.4. Information for Analysis 132

C12. CHAPTER 12 - AE BUILDING DESIGN AND LAYOUT 133

C12.1. General 133 C12.2. Building Exteriors 133 C12.3. Interiors, Walls, Roofs, and Ceilings 133 C12.4. Floors and Work Surfaces 133 C12.5. Substantial Dividing Walls 134 C12.6. Exits and Doors 134 C12.7. Emergency Egress 134 C12.8. Passageways 134 C12.9. Roads and Walkways 135 C12.10. Windows and Skylights 135 C12.11. Drains, Sumps, and Sewers 135 C12.12. Hardware 136 C12.13. Ventilation Systems 136 C12.14. Steam for Heating and Processing 136 C12.15. Tunnels 137

C13. CHAPTER 13 - SAFETY REQUIREMENTS FOR SPECIFIC AE 138

AND AE OPERATIONS

C13.1. General 138 C13.2. Properties of Explosives 138 C13.3. Laboratory Operations 140 C13.4. Heat Conditioning of AE 141 C13.5. Spray Painting Loaded AE 142 C13.6. Drying Freshly Painted Loaded AE 142 C13.7. Rework, Disassembly, Renovation, and Maintenance 143 C13.8. AE Loading and Associated Operations 143

8 TABLE OF CONTENTS

C14. CHAPTER 14 - TESTING REQUIREMENTS 148

C14.1. General 148 C14.2. Operating Precautions 148 C14.3. Test Hazards 150 C14.4. Test Clearance 150 C14.5. Warning and Communications Systems 151 C14.6. Specific Items for Test 151 C14.7. Malfunctions 152 C14.8. Ammunition and Dud Recovery 153 C14.9. Personnel Shelters 153 C14.10. Testing of Ammunition or Devices for Small Arms 156 C14.11. Velocity and Pressure Tests 156

C15. CHAPTER 15 - COLLECTION AND DESTRUCTION REQUIREMENTS 157

FOR AE

C15.1. General 157 C15.2. Protection During Disposal Operations 157 C15.3. Collection of AE 157 C15.4. Design and Operation of Collection Systems 158 C15.5. Location of Collection Chambers 160 C15.6. AE Awaiting Destruction 160 C15.7. Containers for Waste Explosives 161 C15.8. Destruction Sites 161 C15.9. Destruction by Burning 164 C15.10. Destruction by Detonation 165 C15.11. Destruction by Neutralization 166 C15.12. Destruction Chambers and Incinerators 166 C15.13. Support in Disposal of Explosives Waste 167

AP1 – APPENDIX 1 - GLOSSARY 168

AP2 – APPENDIX 2 - QD TABLES EXTRACTED FROM DOD 6055.9-STD 177

AP3 – APPENDIX 3 - ECM ORIENTATION FIGURES FROM DOD 6055.9-STD 228

INCLUDED BY REFERENCE

TABLES

C4.T1. Storage Compatibility Mixing Chart 42 C7.T1. Control and Personnel Protection Requirements for Certain Propellant 108 Processing Operations C10.T1. Fire Division Markings 124 C10.T2. Emergency Withdrawal Distances for Nonessential Personnel 127

9 TABLE OF CONTENTS

C11.T1. Risk Matrix Format Example 131 C11.T2. Risk Assessment Definitions Example 131 C14.T1. Separation of Firing Points and Bombproofs 155 C14.T2. Portable Bombproofs and Uses 155 AP2.T1. HD 1.1 IBD and PTRD 178

AP2.T2. HD 1.1 HFD 181

AP2.T3. HFD for Open Stacks of Selected HD 1.1 AE 183 AP2.T4. HD 1.1 ILD from ECM 185

AP2.T5. HD 1.1 ILD 188

AP2.T6. HD 1.1 IMD Hazard Factors 191 AP2.T7. QD For HD 1.1 AE For K = 1.1, 1.25, 2, 2.75, 4.5, and 5 192 AP2.T8. QD for HD 1.1 AE For K = 6, 8, 9, 11, 18, 40 194 AP2.T9. Summary of HD 1.2.1, 1.2.2, AND 1.2.3 QD 196 AP2.T10. HD 1.2.1 QD (IBD, PTR, ILD) for AE With NEWQD > 1.60 lbs [0.73 kg] 198 AP2.T11. HDD for HD 1.2.1 AE Stored in Structures That Can Contribute to 201 the Debris Hazard AP2.T12. HD 1.2.2 QD (IBD, PTR, ILD) For AE with NEWQD < 1.60 lbs [0.73 kg] 203 AP2.T13. HD 1.2.1, 1.2.2, AND 1.2.3 Mixing Rules 205

AP2.T14. HD 1.3 QD 206

AP2.T15. HD 1.4 QD 209

AP2.T16. HD 1.6 QD 210

AP2.T17. Hazard Classifications and Minimum QD for Energetic Liquids 212 AP2.T18. Factors to Use When Converting Energetic Liquid Densities 214 AP2.T19. Energetic Liquid Explosive Equivalent Explosive Weights 215 AP2.T20. QD Criteria for OSHA/NFPA Class I – III Flammable and Combustible 217 Energetic Liquids Storage in Detached Buildings or Tanks AP2.T21. QD Criteria for Energetic Liquid Oxidizer (Excluding Liquid Oxygen) 218 Storage in Detached Buildings or Tanks AP2.T22. QD Criteria for Liquid Oxygen Storage in Detached Buildings or Tanks 220 AP2.T23. QD Criteria for Liquid Hydrogen and Bulk Quantities of Hydrazines 221 AP2.T24. Default Maximum Case Fragment Distances For Intentional Detonations 224 AP2.T25. Maximum Case Fragment Distances for Selected Single Item Detonations 227

FIGURES

C5.F1. Determination of Barricade Height (Equal Height) 84 C5.F2. Determination of Barricade Height (Unequal Height) 84 C5.F3. Determination of Barricade Length 84 C10.F1. Fire Symbol Markings 125 C14.F1. Emplacement of Bombproofs at Firing Points 154 AP3.F1. ECM Orientation Effects on IMD: Side-to-Side Orientation 228 AP3.F2. ECM Orientation Effects on IMD: Side-to-Side Orientation 229 AP3.F3. ECM Orientation Effects on IMD 229

10 TABLE OF CONTENTS

AP3.F4. ECM Orientation Effects on IMD 230 AP3.F5. ECM Orientation Effects on IMD: Canted ECM 230 AP3.F6. ECM Orientation Effects on IMD: ECM of Significantly Different Lengths 231 AP3.F7. ECM Orientation Effects on Barricaded and Unbarricaded IMD and ILD 232

11 ACRONYMS AND ABBREVIATIONS

ACRONYMS AND ABBREVIATIONS

AE ammunition and explosives ACO administrative contracting officer AGM aboveground magazine AGS aboveground structure/site AGS (H) aboveground structure, heavy wall AGS (L) aboveground structure, light AP ammonium perchlorate ASME American Society of Mechanical Engineers

°C degrees Celsius CFR Code of Federal Regulations CG compatibility group COCO contractor-owned, contractor-operated d loading density (used in formulae) D minimum safe distance (used in formulae) DCMA Defense Contract Management Agency DDESB Department of Defense Explosives Safety Board DoD Department of Defense DOT Department of Transportation

ECM earth-covered magazine EED electro-explosive device EIDS extremely insensitive detonating substances ELCG Energetic Liquid Compatibility Group ES exposed site ESD electrostatic discharge

°F degrees Fahrenheit FO foreign object FOE foreign object elimination ft feet

GOCO government-owned, contractor-operated

H heavy wall H/R heavy wall/roof HAN hydroxyl ammonium nitrate HD hazard division HDD hazardous debris distance HE high explosive HEW high explosive weight HFD hazardous fragment distance HMX octogen, nitroamine high explosive

12 ACRONYMS AND ABBREVIATIONS

HPM high performance magazine

IAW in accordance with IBD inhabited building distance ILD intraline distance IMD intermagazine distance IR infrared

JHCS Joint Hazard Classification System

K factor that is dependent upon the risk assumed or permitted kg kilograms kPa kilopascals kV kilovolts ln natural logarithm lb pound LPG liquefied petroleum gas m meters MCE maximum credible event MIL-STD military standard ms milli second

NAVFAC Naval Facilities Engineering Command NEW net explosive weight NEWQD net explosive weight for quantity distance NFPA National Fire Protection Association NG nitroglycerin NPW net propellant weight

OSHA Occupational Safety and Health Administration

Pa Pascal PCO procuring contracting officer PES potential explosion site PETN pentaerythritol tetranitrate PPE personal protective equipment psi pounds per square inch psig pounds per square inch gauge PTR public traffic route PTRD public traffic route distance

Q net explosive weight for quantity distance expressed in kilograms QD quantity distance

13 ACRONYMS AND ABBREVIATIONS

R rear RDX cyclotrimethylenetrinitramine RF radio frequency

S side SG sensitivity group SOP standard operating procedure

TB technical bulletin TEA triethyl aluminum TNT trinitrotoluene TP technical paper

UL Underwriters Laboratories UN United Nations

W net explosive weight for quantity distance expressed in pounds W[Q] net explosive weight for quantity distance in pounds [kilograms] WP white phosphorus

14 REFERENCES

REFERENCES

(a) DoD Instruction 4145.26, “DoD Contractor’s Safety Requirements for Ammunition and

Explosives,” April 9, 2005

(b) DoD 4145.26-M, “DoD Contractors’ Safety Manual for Ammunition and Explosives,”

September 16, 1997 (which is hereby rescinded and superseded, yet will remain applicable and effective for contractual actions entered into on or after September 16, 1997 and before the reissue date.)

(c) DoD 6055.9-STD, “DoD Ammunition and Explosives Safety Standards,” February 29, 2008

(d) Subpart 223.370 of the Defense Federal Acquisition Regulation Supplement, “Safety

Precautions for Ammunition and Explosives.” December 9, 2005

(e) DoD Instruction 6055.7, “Accident Investigation, Reporting, and Record Keeping,”

October 3, 2000

(f) Parts 1904 and 1910 of title 29, Code of Federal Regulations (CFR)

(g) Parts 100-199 of title 49, CFR

(h) Military Standard (MIL-STD)-398, “Shields, Operational for Ammunition Operations, Criteria for Design of and Tests for Acceptance,” November 5, 19761

(i) Technical Bulletin (TB) 700-2/Naval Sea Systems Command Instruction (NAVSEAINST)

8020.8B/Technical Order (TO) 11A-1-47/Defense Logistics Agency Regulations (DLAR) 8220.1, “Department of Defense Ammunition and Explosives Hazard Classification Procedures,” January 5, 19982

(j) National Fire Protection Association (NFPA) Manual 491M.5, “Hazardous Chemical Reactions,” current edition3

(k) Department of Defense Explosives Safety Board (DDESB) Technical Paper (TP) No. 13, “Prediction of Building Debris for Quantity-Distance Siting,” April 19912

(l) DDESB TP No. 16, “Methodologies for Calculating Primary Fragment Characteristics,” October 17, 20052

(m) DDESB TP No. 15, “Approved Protective Construction (Version 2.0),” June 20042

(n) Technical Manual (TM) 5-1300/Naval Facilities Engineering Command (NAVFAC) P- 397/Air Force Manual (AFM) 88-22, “Structures to Resist the Effects of Accidental Explosions,” November 28, 19902

(o) DDESB TP No. 10, Change 3, “Methodology For Chemical Hazard Prediction," June 19802

(p) American Society of Mechanical Engineers Boiler and Pressure Vessel Code, Section VIII, “Rules for Construction of Pressure Vessels,” Division 1/Division 2, current version4

1 Defense Automated Printing, 700 Robbins Avenue, Philadelphia, PA 19111; Phone: 215-697-

2 Department of Defense Explosives Safety Board (DDESB), Room 856C, Hoffman Building I, 2461 Eisenhower Avenue, Alexandria, VA 22331-0600; Phone: 703-325-0891; Fax: 703- 325-6227

3 NFPA, 1 Batterymarch Park, Quincy, MA 02169-7471; Phone: 617-770-3000; Fax: 617-770-

4 ASME International, 22 Law Drive, Box 2900, Fairfield, NJ 07007-2900; Phone: 800-843- 2763; International: 973-882-1167; Fax: 973-882-1717

15 REFERENCES

(q) NFPA 30, “Flammable and Combustible Liquids Code,” current version3

(r) NFPA 70, “National Electric Code,” current version3

(s) NFPA 91, “Standard for Exhaust Systems for Air Conveying of Vapors, Gases, Mists, and

Noncombustible Particulate Solids,” current version3

(t) NFPA 780, “Standard for the Installation of Lightning Protection Systems,” current version3

(u) NFPA 77, “Recommended Practice on Static Electricity,” current version3

(v) NFPA 10, “Standard for Portable Fire Extinguishers,” current version3

(w) NFPA 704, “Standard System for the Identification of the Hazards of Materials for

Emergency Response,” current version3

(x) NFPA 13, “Standard for the Installation of Sprinkler Systems,” current version3

(y) NFPA 15, “Standard for Water Spray Fixed System for Fire Protection,” current edition3

(z) MIL-STD-882D, “Standard Practice for System Safety,” February 10, 20001

(aa) NFPA 101, “Life Safety Code,” current edition3

(ab) NFPA 80, “Standard for Fire Doors and Other Opening Protectives,” current edition3

(ac) NFPA 33, “Standard for Spray Application Using Flammable or Combustible Materials,” current version3

(ad) Federal Aviation Administration Handbook5

(ae) DDESB TP No. 18, “Minimum Qualifications for Unexploded Ordnance (UXO)

Technicians and Personnel,” 20 December 20042

(af) NFPA 430, “Code for the Storage of Liquid and Solid Oxidizers,” current version3

(ag) Wilton, C., “Investigation of the Explosive Potential of the Hybrid Propellant Combinations

N2O4/PBAN and CTF/PBAN,” AFRPL-TR-67-124, 1967 (AD A003 595)6

(ah) NFPA 251, “Standard Methods of Tests of Fire Resistance of Building Construction and

Material,” current version3

(ai) NFPA 55, “Standard for the Storage, Use, and Handling of Compressed Gases and Cryogenic Fluids in Portable and Stationary Containers, Cylinders, and Tanks,” current version3

(aj) Zabetakis, M. G. and Burgess, D. S., “Research on the Hazards Associated With the Production and Handling of Liquid Hydrogen,” U.S. Department of the Interior, Bureau of Mines Report 5707, 19617

5 Available at http://nasdocs.faa.gov/nasiHTML/FAAStandards/faa-hdbk-006/HDBK006.pdf 6 Defense Technical Information Center, Fort Belvoir, VA 22060; Phone: 800-225-3842 7 Chemical Propulsion Information Agency, Accession Number 1964-0291, The Johns Hopkins

University, 10630 Little Patuxent Parkway, Suite 202, Columbia, MD 21044-3204; Phone:

410-992-7300; Fax: 410-730-4969

16 CHAPTER 1

C1. CHAPTER 1

INTRODUCTION

C1.1. PURPOSE

C1.1.1. This Manual provides safety requirements, guidance and information to minimize potential accidents that could interrupt Department of Defense (DoD) operations, delay DoD contract production, damage DoD property, cause injury to DoD personnel, or endanger the public during DoD contract work or services involving ammunition and explosives (AE). The Manual contains the minimum contractual safety requirements to support DoD objectives. These requirements are not a complete safety program, and this Manual does not relieve a contractor from complying with Federal, State, interstate, and local laws and regulations.

C1.1.2. Criteria provided by these Standards are provided in English units (e.g., ft, lb, psi) with metric equivalents shown in brackets (e.g., [m, kg, kPa]).

C1.2. APPLICABILITY. When included in or properly incorporated into their contracts, subcontracts, purchase orders, or other procurement methods and made applicable to the contractor (or to their subcontractors), these safety requirements apply to contractors and subcontractors handling ammunition or explosives. Nothing in this Manual should be construed as making the Department of Defense a controlling employer under Occupational Safety and Health Administration (OSHA) regulations and standards.

C1.3. MANDATORY REQUIREMENTS AND ADVISORY GUIDANCE. This Manual uses the term “shall” or an affirmative statement to indicate mandatory requirements. The terms “should” and “may” are advisory in nature.

C1.4. COMPLIANCE WITH MANDATORY REQUIREMENTS. The Department of Defense requires compliance with mandatory provisions of this Manual and applicable portions of Reference (c). In order to provide consistent and current information to all DoD AE contractors, quantity distance (QD) tables and formulae in Reference (c) are incorporated by reference in Chapter 5 of this Manual. The procuring contracting officers (PCOs) may grant contract-specific waivers to mandatory provisions of this Manual. For government-owned/contractor-operated facilities, requests for waivers of safety requirements shall be processed via the administrative contracting officer (ACO) or PCO through the explosives safety office of the Military Service that owns the facilities for review and approval in accordance with the Military Service requirements. For contractor-owned facilities, requests for waivers from mandatory provisions of this Manual shall be processed through the ACO to the PCO.

17 CHAPTER 1

C1.4.1.1. In the pre-award phase, during pre-award surveys, noncompliance with mandatory safety requirements normally results in a recommendation of “no award.” Any noncompliant condition shall be resolved during the pre-award survey. Contractors may choose to correct the deficiencies immediately, offer a letter of intent to correct the deficiencies (which will become binding upon award of contract), or request that the PCO accept specifically identified existing conditions of facilities (contract-specific waiver).

C1.4.1.2. In the post-award phase, the contractor has 30 days from the date of notification by the ACO to correct the non-compliant condition and inform the ACO of the corrective actions taken. The contracting officer may direct a different time period for the correction of any noncompliance. If the contractor refuses or fails to correct any noncompliance within the time period specified by the ACO, the Government has the right to direct the contractor to cease performance on all or part of affected contracts. When the contractor cannot comply with the mandatory safety requirements of the contract, the contractor may develop and submit a request for a waiver through the ACO to the PCO for the final determination. For DoD-owned, contractor-operated facilities, the PCO coordinates with the explosives safety office of the Military Service that owns the facilities for review and approval in accordance with the Military Service requirements. The request shall contain complete information concerning the requirements violated, actions planned to minimize the hazard, and a proposed date for correction of the non-compliant conditions.

C1.5. PRE-AWARD SAFETY SURVEY

C1.5.1. The PCO will request a DoD pre-award safety survey to help determine contractor capability. DoD safety personnel conduct pre-award surveys to evaluate each prospective contractor's ability to comply with contract safety requirements. While the pre-award safety survey is an opportunity for the contractor to request clarification of any safety requirement or other AE issue that may affect the contractor's ability to comply, any such clarification must be issued by the contracting officer. During pre-award surveys, the contractor shall provide:

C1.5.1.1. Site plans conforming to subparagraphs C1.8.5.1. through C1.8.5.5. for proposed facilities to be used in contract performance.

C1.5.1.2. Evidence of implementation of a safety program containing at least the mandatory requirements described in Chapter 3 of this Manual.

C1.5.1.3. General description of proposed contract facilities, including size, building layouts, construction details, and fire resistive capabilities.

C1.5.1.4. Fire prevention program and available firefighting resources, including local agreements or other documentation demonstrating coordination.

C1.5.1.5. Copies of required licenses and permits or demonstration of the ability to obtain approvals necessary to support the proposed contract.

18 CHAPTER 1

C1.5.1.6. A safety history including accident experience; safety survey or audit reports by insurance carriers or Federal, State, and local authorities; and any variances, exemptions, or waivers of safety or fire protection requirements issued by Federal, State, or local authorities.

C1.5.1.7. Proposed operations and equipment to include process flow narrative/diagram, proposed facility or equipment changes, proposed hazard analysis, and proposed procedures for all phases of AE operations.

C1.5.1.8. Subcontractor information.

C1.5.8.1. Identification of all subcontractors proposed for the AE work.

C1.5.8.2. Proposed methods used to evaluate the capability of the subcontractor to comply with the requirements of this Manual.

C1.5.8.3. Proposed methods used to ensure subcontractor compliance.

C1.6. PRE-OPERATIONAL SAFETY SURVEY

C1.6.1. The Department of Defense reserves the right to conduct a pre-operational survey after contract award in these situations:

C1.6.1.1. Contractor has limited experience with the item.

C1.6.1.2. After major new construction.

C1.6.1.3. After major modifications.

C1.6.1.4. After an AE accident.

C1.6.2. When these situations occur, the contractor shall provide sufficient notification to the ACO and Defense Contract Management Agency (DCMA) contract safety personnel, to provide adequate time for the Department of Defense to schedule and perform a preoperational survey.

C1.7. POST-AWARD CONTRACTOR RESPONSIBILITIES. The contractor shall:

C1.7.1. Comply with the requirements of this Manual and any other safety requirements contained within the contract.

C1.7.2. Develop and implement a demonstrable safety program, including operational procedures, intended to prevent AE-related accidents.

C1.7.3. Designate qualified individuals to administer and implement this safety program.

19 CHAPTER 1

C1.7.4. Prepare and keep available for review all hazard analyses used to justify alternative methods of hazards control implemented in order to comply with the mandatory requirements in this Manual.

C1.7.5. http://cyberregs.citation.com/cgi-exe/cpage.dll - pagelist#pagelistProvide access to facilities and safety program documentation to DoD safety representatives.

C1.7.6. Report and investigate AE accidents in accordance with Chapter 2 of this Manual.

C1.7.7. Provide identification and location of subcontractors to the ACO for notification or approval in accordance with terms of the contract.

C1.7.8. Establish and implement management controls to ensure AE subcontractors comply with paragraphs C1.7.1. through C1.7.7. of this section.

C1.8. SITE AND CONSTRUCTION PLANS

C1.8.1. Contractors shall maintain a current site plan that demonstrates compliance with QD requirements for all AE locations within their facility. In addition, contractors shall prepare and submit site and construction plans for all new construction or major modification of facilities for AE activities and for any facilities potentially exposed to AE hazards if improperly located.

Contractors shall provide copies of any of these documents to the Department of Defense upon request. For DoD facilities, site plans are required per paragraph C5.4.1. of Reference (c).

C1.8.2. When the place of performance of the contract is at DoD-owned/contractor-operated facilities, site and construction plans shall be prepared and processed via the ACO and/or PCO through the explosives safety office of the Military Service that owns the facilities for review and approval in accordance with Reference (c) and the Military Service requirements.

C1.8.3. For contractor-owned, contractor-operated (COCO) facilities, the contractor shall submit, through the ACO to the PCO, site and construction plans for all new construction or major modification of facilities for AE activities and for the facilities that may be exposed to AE hazards if improperly located. The contractor shall provide sufficient copies for the review process. The contractor shall not begin construction or modification of proposed facilities until receiving site and construction plan approval from the PCO through the ACO.

C1.8.4. Minor new construction, changes, and modifications of existing COCO AE facilities involving hazard division (HD) or changes that add or remove small portable operating buildings and magazines may not require formal site plan submission. “Minor” applies to all changes that involve only 1.4S HD materials. “Minor” also applies to changes of other HD materials that do not increase the existing net explosive weight for quantity distance (NEWQD) or maximum credible event (MCE) for an AE facility and that do not extend any QD arcs beyond existing inhabited building and public traffic route distance (PTRD) arcs. The contractor shall notify the ACO of a potential minor modification or change and request a determination.

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C1.8.5. Site plans shall comply with the following:

C1.8.5.1. Plans shall include maps and drawings which are legible, accurate, and of a scale that permits easy determination of essential details. For general layout of buildings, this is normally a scale of 1 inch to 400 ft (or metric equivalent) or less. Site plans may require other-scaled drawings, which provide details of construction, structure relationships within the project area, barricades, or other unique details. Plans may also include pictures to illustrate details and videotapes of MCE testing data.

C1.8.5.2. Maps and drawings shall identify distances between all potential explosion sites (PESs), all exposed sites (ESs) within the facility, the facility boundary, any additional property under contractor control, ESs on adjacent property when applicable, public railways and highways, power transmission lines, and other utilities.

C1.8.5.3. Plans shall identify and briefly describe all PESs and all ESs within any applicable inhabited building distance (IBD) of a PES. Site plans for major new construction or modification shall also identify and briefly describe all PESs whose IBD arc includes the proposed new or modified site. Fragmentation distances shall be included for IBD arcs, when applicable. Plans shall identify and briefly describe all PESs and all ESs out to 110 percent of IBD of a PES.

C1.8.5.4. Plans shall include the maximum net explosive weight(s) (NEW(s)) and the HD of all PESs and, when applicable, shall include MCE information and maximum NEW for each room or bay. Plans shall also include engineering or test data when substituting construction or shielding for distance to protect from fragmentation or overpressure.

C1.8.5.5. Personnel in buildings are provided a high degree of protection; however, glass breakage and building debris may cause some injuries to personnel. New or modified facilities, located within the IBD arc of any PES, that will include glass panels and will contain personnel shall have a glass breakage personnel hazards risk assessment conducted. Elimination of glass surfaces is the best control. If determined to be necessary, reducing the use of glass or the size of any glass surfaces and the use of blast resistant glass will provide some relief. For new construction, building design characteristics, to include consideration of how any required glass surfaces are oriented and use of blast resistant glass can reduce glass breakage and structural damage.

C1.8.5.6. Plans shall include a topographical map in sufficient detail to permit evaluation when the contractor uses natural terrain for barricading to reduce fragment distance.

C1.8.6. Construction plans for proposed facilities shall contain the information required in subparagraphs C1.8.5.1. through C1.8.5.5. as well as construction details of dividing walls, venting surfaces, firewalls, roofs, operational shields, barricades, exits, ventilation systems and equipment, AE waste disposal systems, lightning protection systems, grounding systems, processing equipment auxiliary support structures, and general materials of construction, as applicable.

21 CHAPTER 2

C2. CHAPTER 2

ACCIDENT INVESTIGATION AND REPORTING

C2.1. GENERAL. This section contains requirements for investigating and reporting accidents involving AE. Nothing in the reporting requirements contained in this Manual relieves the contractor from notifying Federal, State, or local agencies.

C2.2. REPORTING CRITERIA. Per Reference (c) and DoDI 6055.7 (Reference (e)), the contractor shall investigate and report all AE accidents that result in one or more of the below listed outcomes to the ACO and the cognizant DCMA contract safety specialist. The ACO/DCMA contract safety specialist shall notify the Service and the Service shall notify the

DDESB.

C2.2.1. One or more fatalities.

C2.2.2. One or more lost-work day cases with days away from work as defined by part 1904 of title 29, CFR (Reference (f)).

C2.2.3. Five or more non-fatal injuries (with or without lost workdays).

C2.2.4. Damage to government property exceeding $20,000.

C2.2.5. Delay in delivery schedule exceeding 24 hours. (This requirement does not constitute a waiver or amendment of any delivery schedule required by the contract.)

C2.2.6. Contractually required notifications of accidents other than in paragraphs C2.2.1.

through C2.2.5.

C2.2.7. Any accident that may degrade operational or production capability or is likely to arouse media interest.

C2.3. ACCIDENT INVESTIGATION REQUIREMENTS. The contractor is contractually responsible for investigating and reporting AE accidents; however, the Government retains the right to conduct an independent DoD investigation when circumstances warrant. DCMA safety representatives will monitor contractor on-site accident investigations but will not formally participate. Contractors experiencing an AE accident shall take those actions necessary to protect life and health, limit property damage, and preserve evidence at the accident scene. In the initial telephonic and written accident reports (See sections C2.4 and C2.5) the contractor shall advise the contracting officer and the DCMA safety representative of the incident. Based on initial reports, the contracting officer may require an additional, more comprehensive technical investigation by the contractor or by an independent DoD investigation team.

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C2.4. TELEPHONE REPORT. The contractor shall report any accident described in section C2.2. by telephone, with e-mail confirmation to the ACO and cognizant DCMA contract safety specialist as soon as practicable but not later than 3 hours after the accident. The telephone report with e-mail confirmation should use the report format outlined in section C2.5. and provide all preliminary accident information available.

C2.5. WRITTEN REPORT

C2.5.1. The contractor shall submit a written report by the end of the second business day after accident occurrence to the ACO and the cognizant DCMA contract safety specialist who shall route to the Service. The Service shall route to the DDESB. This report may be provided electronically or in hard copy. The report shall include:

C2.5.1.1. Contractor's name and location.

C2.5.1.2. Date, local time, plant or facility location of the accident.

C2.5.1.3. Type of accident (explosion, fire, loss, other).

C2.5.1.4. Contract, subcontract, or purchase order.

C2.5.1.5. Item nomenclature, hazard classification, lot number.

C2.5.1.6. Accident narrative.

C2.5.1.7. Number of fatalities, injuries, degree of injuries.

C2.5.1.8. Description of property damage and actual or estimated cost.

C2.5.1.9. Quantity of energetic material involved (weight, units, rounds).

C2.5.1.10. Probable cause(s).

C2.5.1.11. Corrective action taken or planned.

C2.5.1.12. Summary of Lessons Learned and Recommendations.

C2.5.1.13. Effect on production.

C2.5.1.14. Name, title or position, and phone number of person submitting the report.

C2.5.1.15. Remarks.

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C2.5.2. The contractor shall provide to the ACO, DCMA contract safety specialist, and, through the Service, to DDESB supplemental information to the initial report within 30 days of the accident occurrence and at 30-day intervals until the investigation is complete.

C2.6. TECHNICAL ACCIDENT INVESTIGATION AND REPORT. Based upon the seriousness of the accident and criticality of the munitions or explosives involved, the PCO may require an additional, more comprehensive technical investigation by the contractor or by an independent DoD investigation team. Upon determination by the PCO that a DoD investigation is required, the PCO will immediately advise the contractor. The technical investigation report shall include details such as missile fragmentation maps, photographs, detailed description of accident, event time line, chemistry, effects on adjacent operations, structural and equipment damage, QD drawings, findings, and conclusions. If the contractor performs the special technical accident investigation, the contractor shall forward the report through the ACO to the PCO within 60 days unless otherwise directed by the PCO. Any of these investigations and studies reports shall also be submitted through the Service to the DDESB.

24 CHAPTER 3

C3. CHAPTER 3

GENERAL SAFETY REQUIREMENTS

C3.1. GENERAL. This chapter provides general safety requirements for all AE operations addressed in this Manual. When these practices exceed or differ from local or national codes or requirements, the more restrictive shall apply.

C3.2. PERSONNEL AND MATERIAL LIMITS

C3.2.1. The cardinal principle of AE safety is to limit exposure to a minimum number of personnel, for a minimum amount of time, to the minimum amount of the hazardous material consistent with safe and efficient operations. To implement this principle, contractors shall establish AE and personnel limits at all AE operations. Contractors shall examine all operations and devise methods for reducing the number of people exposed, the time of exposure, and the quantity of material subject to a single incident.

C3.2.2. Determination of AE limits requires a careful analysis of all facts including normal operation times, intraplant transportation methods, net explosive weight, and the chemical and physical characteristics of the AE. More sensitive and more energetic hazardous materials require lower limits. Contractors shall base limits on safe and efficient operational requirements and not on the maximum quantity of explosives allowed by QD requirements. Contractors may express limits either in units of weight or in the number of each item (tray, box, rack, or other unit) that operators can more easily observe and control.

C3.2.3. Determination of personnel limits requires separation of unrelated jobs and controlled limited access of unrelated personnel from a particular hazardous operation. Hazard analysis shall determine the need for dividing walls, firewalls, or operational shields to protect operators at frequent, consecutive operations in the same room or building. Personnel limits shall include a maximum number of operators and a maximum number of transients including supervisors, workers, and visitors.

C3.2.4. Military Services may have documentation which requires contractors to use special procedures for developing standard operating procedures (SOPs). Therefore, before starting operations involving AE, qualified personnel shall develop, review, and approve written procedures in accordance with the Military Services guidelines or the instructions below.

C3.3. SOPs. Clearly written procedures are essential to avoid operator errors and ensure process control. Therefore, before starting operations involving AE, qualified personnel shall develop, review, and approve written procedures.

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C3.3.1. Preparation. Contractors shall examine all aspects of an AE operation and shall determine a safe and orderly course of action for accomplishing the work. Certain AE operations may require controlled tests to validate the safety of procedural steps in the SOP. At a minimum, SOPs shall include:

C3.3.1.1. The specific hazards associated with the process.

C3.3.1.2. Indicators for identifying abnormal process conditions.

C3.3.1.3. Emergency procedures. (SOP may include a separate emergency procedure SOP by reference.)

C3.3.1.4. Personal protective clothing and equipment required for process personnel.

C3.3.1.5. Personnel and AE limits.

C3.3.1.6. Specific equipment, tools, and expendable supplies permitted for use by the process operator.

C3.3.1.7. The location and sequence of job steps the operator is to follow in performing the work.

C3.3.1.8. Instructions for spill cleanup and disposal of any scrap and waste AE.

C3.3.2. Dissemination and Posting. The supervisors shall be responsible for explaining duties prescribed by the SOP to all personnel involved in an AE operation. Written operating procedures need not be posted, but shall be available at the workstation to personnel involved in AE processes and operations or AE equipment maintenance.

C3.3.3. Training. Personnel shall receive appropriate training before performing work that involves exposure to AE. The training shall include specific safety and health hazards, emergency procedures including shutdown, and safe work practices applicable to the employee's job tasks. The contractor shall ensure that each employee involved in an AE process has received and understood the training and receives appropriate refresher training. The contractor shall prepare a record that contains the identity of the employee, the date of training, and the means used to verify that the employee understood the training.

C3.3.4. Emergency Procedures. The contractor shall instruct employees on procedures to follow in the event of electrical storms, utility or mechanical failures, equipment failures, process abnormalities, and other emergencies occurring during AE operations.

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C3.3.5. Control and Monitoring. The contractor shall establish and maintain written procedures that define methods for controlling and monitoring outside subcontractors who perform work on the contractor's premises that may affect AE operations. The procedures shall also include: the method used by the contractor to determine that subcontractors are qualified to perform the work safely; and the steps that will be followed by the contractor to limit the subcontractors’ exposure to AE operations.

C3.3.6. Revalidation. The managing authority shall ensure that qualified personnel review and update SOPs as often as necessary to reflect improved methods, equipment substitutions, facility modifications, or process changes.

C3.4. STORAGE IN OPERATING BUILDINGS

C3.4.1. The contractor may store limited quantities of hazardous materials in Classes 2 through 9, as defined by part 173 of title 49, CFR (Reference (g)), which are essential for current operations in an operating building.

C3.4.2. The contractor shall store AE materials that exceed the minimum quantity necessary for sustained operations in a service magazine located no closer than intraline distance (ILD) (based on the quantity in the magazine) from the operating building or area. If ILD is not available for a separate service magazine, the contractor may designate storage locations closer than the ILD or within the operating building. The NEW of AE in any designated outside storage location at less than ILD shall be added to the NEW in the operating building and shall be considered as part of the operating building when measuring QD separation distances to other ESs. Designated storage locations must be located at distances to prevent immediate propagation of the stored AE in the event of an explosion in the operating area. The quantity of AE material in the designated storage location shall not exceed that needed for one half of a work shift. The contractor should consider personnel exposure, structural containment afforded, and the venting ability of the proposed storage location when determining where to locate a designated storage location. When storage containers are designed to completely contain all fragments, debris, and overpressure, AE material may be stored without regard to QD requirements listed in paragraph C5.1.2. In-process AE materials and subassemblies awaiting subsequent steps in the manufacturing process are not considered storage and are not subject to the half of a work shift limitation.

C3.4.3. At the end of the workday, personnel should remove all AE material from processing equipment and store it in an appropriate magazine or designated storage location. If operationally required, personnel may store in-process AE materials in the building during non-operating hours provided the physical characteristics and stability of the AE materials are not degraded and the AE material would not compromise the safety of the process equipment or personnel when the process is restarted.

27 CHAPTER 3

C3.4.4. The contractor may use a separate enclosed room or bay in an operating building specifically adapted for the interim storage of production items awaiting the results of testing before final pack-out. The NEW of the interim storage facility shall be added to the total NEW of the operating building for QD determination. The room or bay must afford the equivalent of service magazine distance protection to other parts of the building. Such a room or bay is limited to its defined and designed function and items, but is not subject to the one half of a work shift limitation for the building or the ultimate pack-out operation.

C3.5. HOUSEKEEPING IN HAZARDOUS AREAS

C3.5.1. Contractors shall keep structures containing AE clean and orderly.

C3.5.2. Contractors shall establish a regular cleaning program to maintain safe conditions.

Personnel shall not perform general cleaning concurrently with hazardous operations.

C3.5.3. Explosives and explosive dusts shall not be allowed to accumulate on structural members, radiators, heating coils, steam, gas, air or water supply pipes, or electrical fixtures.

C3.5.4. Contractors shall use proper design of equipment, training of employees, and catch or splash pans to prevent spillage of explosives and other hazardous materials. Operators shall promptly remove spillage of explosives and hazardous materials following proper procedures established per section C8.4.

C3.5.5. Personnel shall use cleaning methods, such as hot water, steam, etc., that do not create ignition hazards for cleaning floors in buildings containing explosives. When these methods are impractical, personnel may use nonabrasive sweeping compounds that are compatible with the explosives involved. Flammable compounds shall not be used.

Combustible sweeping compounds (closed cup flash point less than 230ºF) are acceptable for use. Personnel shall not use sweeping compounds containing wax on conductive floors if the wax can reduce conductivity. Personnel shall not use cleaning agents containing alkalis in areas with nitrated organic explosives, since these materials are incompatible and can form sensitive explosive compounds.

C3.5.6. Cleaning methods may use nonferrous wire brushes to clean explosives-processing equipment only when other methods of cleaning are ineffective. A thorough inspection should follow such cleaning to ensure that no wire bristles remain in the equipment. This also applies to cleaning magnesium ingot or other metal molds used in explosives processing. Cleaning methods should substitute fiber brushes for hairbrushes to reduce generation of static.

C3.5.7. Contractors shall dispose of all loose explosives swept up from floors of operating buildings. Responsible personnel shall thoroughly inspect and determine disposition of explosives recovered from sources other than ammunition breakdown operations and equipment.

28 CHAPTER 3

C3.6. EXPLOSIVES WASTE IN OPERATING AREAS

C3.6.1. Explosives safety shall not be compromised while meeting environmental considerations.

C3.6.2. All waste material generated in an explosives area shall require analysis to determine appropriate methods for safe handling and disposition. All explosives waste and contaminated materials shall be kept in covered containers marked to indicate their contents, preferably located in isolated bays or outside the buildings.

C3.6.3. Containers for scrap black powder shall contain water. Waste pyrotechnic, tracer, flare, and similar compositions shall be totally immersed in water, mineral oil, or fuel oil in the waste containers, unless a hazard analysis indicates that it is unnecessary. Waste-initiating explosives shall be kept to a minimum, usually under water or other desensitizing media, and shall be handled with great care.